Download Brother BE-438C Instruction manual

BE-438C
INSTRUCTION MANUAL
Please read this manual before using the machine.
Please keep this manual within easy reach for quick reference.
ELECTRONIC LOCKSTITCH BUTTON SEWER
Thank you very much for buying a BROTHER sewing machine. Before using your new machine, please read the safety
instructions below and the explanations given in the instruction manual.
With industrial sewing machines, it is normal to carry out work while positioned directly in front of moving parts such as the
needle and thread take-up lever, and consequently there is always a danger of injury that can be caused by these parts.
Follow the instructions from training personnel and instructors regarding safe and correct operation before operating the
machine so that you will know how to use it correctly.
SAFETY INSTRUCTIONS
1. Safety indications and their meanings
This instruction manual and the indications and symbols that are used on the machine itself are provided in order to ensure
safe operation of this machine and to prevent accidents and injury to yourself or other people.
The meanings of these indications and symbols are given below.
Indications
DANGER
The instructions which follow this term indicate situations where failure to follow the
instructions will almost certainly result in death or severe injury.
CAUTION
The instructions which follow this term indicate situations where failure to follow the
instructions could cause injury when using the machine or physical damage to equipment
and surroundings.
Symbols
i
···········
This symbol ( ) indicates something that you should be careful of. The picture inside the triangle
indicates the nature of the caution that must be taken.
(For example, the symbol at left means “beware of injury”.)
···········
This symbol (
···········
This symbol ( ) indicates something that you must do. The picture inside the circle indicates the
nature of the thing that must be done.
(For example, the symbol at left means “you must make the ground connection”.)
) indicates something that you must not do.
BE-438C
2. Notes on safety
DANGER
Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before
opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury.
CAUTION
Environmental requirements
Use the sewing machine in an area which is free from
sources of strong electrical noise such as highfrequency welders.
Sources of strong electrical noise may cause problems with correct operation.
Any fluctuations in the power supply voltage should
be within ±10% of the rated voltage for the machine.
Voltage fluctuations which are greater than this may
cause problems with correct operation.
The power supply capacity should be greater than the
requirements for the sewing machine’s electrical
consumption.
Insufficient power supply capacity may cause problems with correct operation.
The ambient temperature should be within the range
of 5°C to 35°C during use.
Temperatures which are lower or higher than this may
cause problems with correct operation.
The relative humidity should be within the range of
45% to 85% during use, and no dew formation should
occur in any devices.
Excessively dry or humid environments and dew formation may cause problems with correct operation.
Avoid exposure to direct sunlight during use.
Exposure to direct sunlight may cause problems with
correct operation.
In the event of an electrical storm, turn off the power
and disconnect the power cord from the wall outlet.
Lightning may cause problems with correct operation.
Installation
Machine installation should only be carried out by a
qualified technician.
Contact your Brother dealer or a qualified electrician
for any electrical work that may need to be done.
The sewing machine weighs more than 52 kg. The
installation should be carried out by two or more
people.
Do not connect the power cord until installation is
complete, otherwise the machine may operate if the
foot switch is depressed by mistake, which could
result in injury.
Hold the machine head with both hands when tilting it
back or returning it to its original position.
Furthermore, after tilting back the machine head, do
not push the face plate side or the pulley side from
above, as this could cause the machine head to
topple over, which may result in personal injury or
damage to the machine.
All cords should be secured at least 25 mm away
from any moving parts. Furthermore, do not
excessively bend the cords or secure them too firmly
with staples, otherwise there is the danger that fire or
electric shocks could occur.
Install the belt covers to the machine head and motor.
If using a work table which has casters, the casters
should be secured in such a way so that they cannot
move.
Be sure to wear protective goggles and gloves when
handling the lubricating oil and grease, so that they
do not get into your eyes or onto your skin, otherwise
inflammation can result.
Furthermore, do not drink the oil or eat the grease
under any circumstances, as they can cause vomiting
and diarrhoea.
Keep the oil out of the reach of children.
Be sure to connect the ground. If the ground connection is not secure, you run a high risk of receiving a
serious electric shock, and problems with correct
operation may also occur.
BE-438C
ii
CAUTION
Sewing
This sewing machine should only be used by operators who have received the necessary training in safe
use beforehand.
If using a work table which has casters, the casters
should be secured in such a way so that they cannot
move.
The sewing machine should not be used for any
applications other than sewing.
Attach all safety devices before using the sewing
machine. If the machine is used without these
devices attached, injury may result.
Be sure to wear protective goggles when using the
machine.
If goggles are not worn, there is the danger that if a
needle breaks, parts of the broken needle may enter
your eyes and injury may result.
Do not touch any of the moving parts or press any
objects against the machine while sewing, as this
may result in personal injury or damage to the
machine.
Set the needle to the needle up stop position before
turning off the power.
If this is not done, the wiper may strike the needle,
which might cause the needle to break.
If an error occurs in machine operation, or if abnormal
noises or smells are noticed, immediately turn off the
power switch. Then contact your nearest Brother
dealer or a qualified technician.
Turn off the power switch at the following times,
otherwise the machine may operate if the foot switch
is depressed by mistake, which could result in injury.
• When threading the needle
• When replacing the needle and bobbin
• When not using the machine and when leaving the
machine unattended
If the machine develops a problem, contact your
nearest Brother dealer or a qualified technician.
Cleaning
Set the needle to the needle up stop position before
turning off the power.
If this is not done, the wiper may strike the needle,
which might cause the needle to break.
Turn off the power switch before carrying out
cleaning, otherwise the machine may operate if the
foot switch is depressed by mistake, which could
result in injury.
Be sure to wear protective goggles and gloves when
handling the lubricating oil and grease, so that they
do not get into your eyes or onto your skin, otherwise
inflammation can result.
Furthermore, do not drink the oil or eat the grease
under any circumstances, as they can cause vomiting
and diarrhoea.
Keep the oil out of the reach of children.
Maintenance and inspection
Maintenance and inspection of the sewing machine
should only be carried out by a qualified technician.
Ask your Brother dealer or a qualified electrician to
carry out any maintenance and inspection of the
electrical system.
Set the needle to the needle up stop position before
turning off the power.
If this is not done, the wiper may strike the needle,
which might cause the needle to break.
Turn off the power switch and disconnect the power
cord from the wall outlet at the following times,
otherwise the machine may operate if the foot switch
is depressed by mistake, which could result in injury.
• When carrying out inspection, adjustment and
maintenance
• When replacing consumable parts such as the rotary hook
If the power switch needs to be left on when carrying
out some adjustment, be extremely careful to observe
all safety precautions.
iii
BE-438C
Hold the machine head with both hands when tilting it
back or returning it to its original position.
Furthermore, after tilting back the machine head, do
not push the face plate side or the pulley side from
above, as this could cause the machine head to
topple over, which may result in personal injury or
damage to the machine.
Use only the proper replacement parts as specified
by Brother.
If any safety devices have been removed, be absolutely sure to re-install them to their original positions
and check that they operate correctly before using the
machine.
Any problems in machine operation which result from
unauthorized modifications to the machine will not be
covered by the warranty.
3. Warning labels
The following warning labels appear on the sewing machine.
Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are
difficult to read, please contact your nearest Brother dealer.
1
2
Safety devices
Eye guard
Finger guard
Thread take-up cover
Thread take-up solenoid cover
Belt cover
Frame side cover, etc.
High temperature warning display
3
4
Be sure to connect the ground. If the ground connection is not secure, you run a high risk of receiving a
serious electric shock, and problems with correct operation may also occur.
5
Direction of operation
Thread take-up
cover
Eye guard
Frame
side cover
2648Q
Belt
cover
Thread take-up
solenoid cover
Finger guard
2750Q
BE-438C
iv
CONTENTS
1. NAME OF EACH PART .............................. 1
9. MAINTENANCE AND INSPECTION .......... 30
9-1. Checking the needle..............................................30
2. SPECIFICATIONS ...................................... 2
9-2. Cleaning the rotary hook .......................................30
2-1. Specifications......................................................... 2
9-3. Lubrication.............................................................31
2-2. Program list............................................................ 3
9-4. Draining the oil ......................................................32
3. INSTALLATION .......................................... 6
9-5. Cleaning the control box air inlet port ....................32
3-1. Power table............................................................ 6
3-2. Installing the control box ........................................ 7
9-6. Cleaning the air holes of belt cover
and frame side cover.............................................32
3-3. Installing the rubber cushions ................................. 8
9-7. Cleaning the eye guard .........................................32
3-4. Installing the oil pan ................................................ 8
10. STANDARD ADJUSTMENTS................... 33
3-5. Installing the cushions............................................. 8
10-1. Adjusting the needle bar height ...........................33
3-6. Installing the switching plate ................................... 9
10-2. Adjusting the needle bar lift amount ....................33
3-7. Installing the machine head .................................... 9
10-3. Adjusting the driver needle guard ........................34
3-8. Installing the head rest.......................................... 10
10-4. Adjusting the needle clearance ...........................34
3-9. Installing the liquid cooling tank,
optional ................................................................. 10
10-5. Adjusting the shuttle race thread guide ...............34
3-10. Installing the operation panel .............................. 11
10-7. Adjusting the movable knife.................................36
3-11. Connecting the ground wire ................................ 11
10-8. Adjusting the button clamp lift amount.................38
3-12. Connecting the cords .......................................... 12
10-9. Adjusting the holding pressure ............................39
3-13. Installing the belt cover ....................................... 14
10-10. Adjusting the position of the button holder.........39
3-14. Installing the foot switch...................................... 14
10-11. Adjusting the needle up stop position ................40
3-15. Installing the spool stand .................................... 15
10-12. Adjusting the thread wiper .................................40
3-16. Installing the button tray...................................... 15
10-13. Checking the input sensor and DIP
switch input........................................................41
10-6. Adjusting the thread take-up amount...................35
3-17. Installing the eye guard....................................... 15
10-14. Checking the input voltage ................................42
4. LUBRICATION........................................... 16
10-15. Clearing all memory settings .............................42
4-1. Lubrication points.................................................. 16
10-16. Moving stitch patterns .......................................43
5. OPERATION .............................................. 17
11. USING THE COUNTERS ......................... 44
11-1. Using the bobbin thread counter .........................44
5-1. Name and function of each operation
panel item ............................................................. 17
5-2. Operating procedure ............................................. 19
6. CHECKING THE SEWING PATTERN........ 21
11-2. Using the production counter...............................44
12. CHANGING FUNCTIONS USING THE
DIP SWITCHES ....................................... 45
12-1. Operation panel DIP switches .............................45
7. CORRECT USE ......................................... 22
12-2. Setting the presser mode ....................................45
7-1. Selecting the needle and thread ........................... 22
12-3. DIP switches inside the control box .....................46
7-2. Installing the needle .............................................. 22
12-4. Using user programs ...........................................47
7-3. Threading the upper thread .................................. 22
7-4. Winding the lower thread ...................................... 23
7-5. Replacing the bobbin case and
threading the thread.............................................. 24
7-6. Thread tension...................................................... 24
7-7. Inserting the button ............................................... 27
7-8. Adjusting the button holder ................................... 27
7-9. Adjustment by the accessory spring ..................... 27
7-10. Replacing the PROM .......................................... 28
13. CHANGING SPECIAL FUNCTIONS
USING THE MEMORY SWITCHES ......... 49
13-1. Using the cycle sewing function ..........................52
14. TABLE OF ERROR CODES..................... 54
15. GAUGE PARTS LIST ............................... 56
16. TROUBLESHOOTING ............................. 57
17. OPTIONAL PARTS .................................. 60
8. SEWING .................................................... 29
BE-438C
1. NAME OF EACH PART
1. NAME OF EACH PART
2650Q
2651Q
Safety devices;
(10) Finger guard
(11) Eye guard
(12) Thread take-up cover
(13) Belt cover
(14) Frame side cover
(15) Thread take-up solenoid cover
(1) Power switch
(2) Control box
(3) Operation panel
(4) Foot switch
(5) Motor
(6) Tension release lever
(7) Pulley
(8) Spool stand
(9) Thread take-up lever
BE-438C
1
2. SPECIFICATIONS
2. SPECIFICATIONS
2-1. Specifications
Stitch formation
Single needle lock stitch
Maximum sewing
speed
Maximum pattern
size
2,500rpm
0 - 6.4 × 0 - 6.4 mm
TQ × 1#12
Needle
Dimensions of
buttons that can be
sewn
Outer diameter of button 8 - 30 mm
(Use the optional button clamp B for diameters of 20 mm or greater.)
Space between the button holes 0 - 6.4 mm
Button clamp height
13 mm max.
Thread knot
Feed mechanism
Knot tied by needle
R-θ intermittent feed mechanism (pulse-motor driven mechanism)
Stitch length
Number of stitches
0.1 - 10.0 mm
Variable (13, 15, 17, 19, 20, 22, 23, 24, 26, 27, 28, 30, 32, 34, 38 stitches
pre-set)
Maximum stitch
number
20,000 stitches (including 10,000 stitches which can be added)
Work clamp lifter
Solenoid type
Rotary hook
Shuttle hook
Wiper device
Standard equipment
Thread trimmer
device
Standard equipment
Thread take-up device
Standard equipment
Data storage method
P-ROM (Any sewing pattern can be added using PS-3000.)
Number of user
programs
Number of cycle
programs
Number of stored
data
Motor
Weights
Power source
2
16
4
49 sewing patterns are set already.
(Up to 100 patterns can be added. Total number of stitches of stored data
which can be added is within 10,000.)
Three-phase 400W induction motor
Machine head: 52kg, Operation panel: 0.6kg,
Control box: 9 - 19kg (depending on destination)
Single-phase 220 - 230V
3-phase 220, 380, 400, 415V
Maximum electric power consumption; 600VA
BE-438C
2. SPECIFICATIONS
2-2. Program list
Sewing patterns are limited as shown in the table below.
(Any program is available as long as the needle drops down in the hole of the button.)
No. of
threads
No. of
crossover
stitches
No. of
stitches
1
6
−
13
2
8
−
15
3
10
−
17
4
12
−
19
16
−
23
20
−
27
6
−
13
10
−
17
12
−
19
5-5-5
−
22
7-7-7
−
28
5-5-5
−
22
26
7-7-7
−
28
10
6-6
1
20
11
8-8
1
24
8-8
3
26
13
10-10
1
28
27
12-12
1
32
6-6
0
26
8-8
0
30
10-10
0
34
12-12
0
38
Program No.
No. of
button holes
*1
2
5
*1
6
*2
7
*2
23
*2
8
*2
9
*2
24
*2
3
25
*2
12
4
*3
14
*3
28
*3
15
*3
29
Sewing
pattern
Standard
sewing length X
Standard
sewing width Y
3.4mm
0mm
0mm
3.4mm
2.6mm
2.4mm
3.4mm
3.4mm
4
BE-438C
3
2. SPECIFICATIONS
No. of
threads
No. of
crossover
stitches
No. of
stitches
16
6-5
1
19
17
8-7
1
23
30
10-9
1
27
18
6-6
1
20
19
8-8
1
24
31
10-10
1
28
45
12-12
1
32
6-6
0
26
8-8
0
30
10-10
0
34
6-6
1
20
10-10
1
28
Program No.
No. of
button holes
*3
20
*3
32
*3
33
*2
21
*2
34
*2*3
Sewing
pattern
0
26
35
10-10
0
34
46
6-6
1
20
47
8-8
1
24
48
10-10
1
28
49
12-12
1
32
*2*3
Standard
sewing width Y
3.4mm
3.4mm
2.4mm
3.4mm
3.4mm
3.4mm
4
6-6
22
Standard
sewing length X
*1 Check that the button hole diameter is 2 mm or greater before using the programs.
*2 Do not use the button lifter spring.
*3 Thread is trimmed after sewing of one side is completed, because there is no crossover thread to be sewn. To continue
sewing to the end, keep the foot switch depressed until sewing of the other side starts, or press the foot switch once more
after sewing of the first side is completed.
4
BE-438C
2. SPECIFICATIONS
The following programs require the solenoid thread wiper (OP).
No. of
threads
No. of
crossover
stitches
No. of
stitches
36
6-6
0
26
37
8-8
0
30
38
10-10
0
34
39
12-12
0
38
6-6
0
26
41
8-8
0
30
42
10-10
0
34
6-6
0
26
Program No.
40
No. of
button holes
Sewing
pattern
4
*
43
*
44
10-10
0
Standard
sewing length X
Standard
sewing width Y
3.4mm
3.4mm
2.4mm
3.4mm
34
* Do not use the button lifter spring.
Note when creating additional data
When sewing data with a small number of stitches (15 stitches or less) is sewn repeatedly (short cycle operation), the upper
shaft motor may overheat and the “E-20” error code may be generated.
BE-438C
5
3. INSTALLATION
3. INSTALLATION
CAUTION
Machine installation should only be carried out by a
qualified technician.
Contact your Brother dealer or a qualified electrician
for any electrical work that may need to be done.
The sewing machine head weighs more than 52 kg.
The installation should be carried out by two or more
people.
Do not connect the power cord until installation is
complete, otherwise the machine may operate if the
foot switch is depressed by mistake, which could
result in injury.
All cords should be secured at least 25 mm away from
any moving parts. Furthermore, do not excessively
bend the cable or secure it too firmly staples,
otherwise there is the danger that fire or electric
shocks could occur.
Be sure to connect the ground. If the ground
connection is not secure, you run the risk of receiving
a serious electric shock, and problems with correct
operation may also occur.
Install the belt covers to the machine head and motor.
Hold the machine head with both hands when tilting
it back or returning it to its original position.
Furthermore, after tilting back the machine head, do
not push the face plate side or the pulley side from
above, as this could cause the machine head to
topple over, which may result in personal injury or
damage to the machine.
3-1. Power table
Use the power table which has been specially designed for each
sewing machines.
* If using a commercially-available table, process it as shown in
the illustration below.
Model code
Table/ legs assembly
127-V30-50001
Note:
The thickness of the table should be at least 40 mm, and it should be strong enough to bear the weight and vibration of the
sewing machine.
If the distance A between the insides of the legs is less than 740 mm, move the control box installation position to the left
(B = 247 mm).
Check that the control box is at least 10 mm away from the leg. If the control box and leg are touching, it could cause the
sewing machine to operate incorrectly.
2739Q
6
BE-438C
3. INSTALLATION
3-2. Installing the control box
Check that the IM sticker is attached to the side of the control box (in the position shown in the illustration).
(BE-438C machine heads can only be used with control boxes which have the IM sticker attached.)
Spacers
Flat washers
Nuts
2454Q
1. Remove the 12 screws (1), and then open the covers (panel mounting assembly (2) and main P.C. board mounting plate
(3)).
Note:
When opening the cover, hold it securely so that it does not fall down.
2. Install the control box with the four accessory bolts (4), spacers (5), flat washers (6) and nuts (7) as shown in the
illustration above.
* Use two nuts (7) at each installation location, and make sure that both nuts are tightened.
3. Close the covers (panel mounting assembly (2) and main P.C. board mounting plate (3)), and tighten them with the screws
(1).
* The main P.C. board mounting plate (3) will be opened again during “3-12. Connecting the cords”, so provisionally
tighten it with the screw (1).
4. Install the power switch (8) with the two screws (9).
5. Secure the power switch cord with the three staples (10).
BE-438C
7
3. INSTALLATION
3-3. Installing the rubber cushions
Install the rubber cushions (1) with the nails (2).
* Install so that the head of the nail does not protrude from
the rubber surface.
2489Q
3-4. Installing the oil pan
2490Q
1. Insert the tabs of the oil pan (2) into the holes for the
cushions (1), and then secure it in place with the five nails
(3) so that the oil pan (2) is not at an angle.
2. While pushing the oil pan (2) down from above, screw in
the oil container (4).
2491Q
3-5. Installing the cushions
Place the two cushions (1) into the holes in the work table so
that the notches are aligned with the tabs in the oil pan, and
secure them in place with the nails (2).
2492Q
8
BE-438C
3. INSTALLATION
3-6. Installing the switching plate
Install the switching plate (1) to the work table with the two
wood screws (2) in the position shown in the illustration.
* The switching plate and the switch bracket which is
attached to the machine head prevent the sewing
machine from starting when the machine head is tilted
back. Therefore, this means that the sewing machine will
not start if the switching plate is not installed.
2493Q
3-7. Installing the machine head
2494Q
Fig. 1
2495Q
2496Q
1. Insert the head hinges (1) into the machine head so that they are parallel, and then secure them with the two set screws
(2).
2. Place the machine head gently on top of the rubber cushions (3) and cushions (4).
Note:
Pull the cords (5) out as shown in the illustration above in order to prevent them from being clamped by the machine
head.
3. Install the hinge presser (6) with the two bolts and two nuts.
4. Check that the head position switch is turned on as shown in Figure 1.
5. Connect the motor cord connector (7) to the accessory cord connector (8).
BE-438C
9
3. INSTALLATION
3-8. Installing the head rest
Tap the head rest (1) into the table hole.
Note:
Tap the head rest securely into the table hole.
2497Q
3-9. Installing the liquid cooling tank, optional
1. Remove the rubber plug, and then push the liquid cooling
tank (1).
2. Tighten it with the set screw (2).
2498Q
10
BE-438C
3. INSTALLATION
3-10. Installing the operation panel
The operation panel can be installed to either the top or bottom of the work table.
2500Q
Top of work table
Bottom of work table
Table
Table
Rubber
sheet
2 - 2.5mm
2499Q
0419Q
1. Install the rear frame (1) to the work table (top or bottom) with the four wood screws (2).
* At this time, tighten the wood screws (2) until the thickness of the rubber sheet is 2 to 2.5 mm.
2. Install the front frame (3) to the rear frame (1) with the four screws (4).
* The vertical orientation of the front frame (3) is the same whether it is installed to the top or the bottom of the work table.
3. Insert the connector cord (5) into the control box through the hole at the side of the box. Refer to “3-12. Connecting the
cords” for details on connecting the cord.
4. Secure the connector cord (5) with the staples (in three places).
3-11. Connecting the ground wire
CAUTION
Be sure to connect the ground. If the ground connection is not secure, you run the risk of receiving a serious electric
shock, and problems with correct operation may also occur.
Connect to the power switch. However, the
black wire is insulated to the inside of the box
and is not used.
Connect to ground
2741Q
BE-438C
11
3. INSTALLATION
3-12. Connecting the cords
2502Q
2503Q
2504Q
2742Q
12
BE-438C
3. INSTALLATION
1. Gently tilt back the machine head.
Note:
After tilting back the machine head, do not push the face side or the pulley side from above.
2. Pass the cord bundle (1) from the machine head through the hole (2) in the work table.
3. Gently return the machine head to its original position.
4. Remove the six screws (3), and then open the control box cover (main P.C. board mounting plate (4)).
Note:
When opening the cover, hold it securely so that it does not fall down.
5. Loosen the two screws (5), and then open the cord presser plate (6) in the direction of the white arrow and pass the cord
bundle (1) through the opening.
6. Remove the screw (7), and then pass it through the terminal holes in the ground cord (8) from the machine head and the
ground cord (9) from the operation panel. Then re-tighten the screw (7) so that the ground cords (8) and (9) are secured
as shown in the illustration.
7. Remove the screw (10), and then pass it through the terminal hole in the ground cord (11) from the upper shaft motor.
Then re-tighten the screw (10) so that the ground cord (11) is secured as shown in the illustration.
Note:
Make sure that the ground connections are secure in order to ensure safety.
8. Securely connect connectors P1 to P8 and P11 as indicated in the table below.
Note:
Check that the connector is facing the correct way, and then insert it firmly until it locks into place.
Furthermore, lock the cord clamp at the top.
Machine head connectors
Connection location
Connection location
on circuit board
Cord clamps used
No. of pins
Cord mark
Head position switch
9-pin
[1A]
P1-A (ORG1)
None
X, Y, Sewing sensor
12-pin
[1]
P1-B (ORG2)
None
Synchronizer
Machine specification
select connector
Thread take-up solenoid
5-pin
[2]
P2 (SYNCHRO)
8-pin
[3]
P3 (SELECT)
None
5-pin
[4]
P4 (SOL2)
(G)(H)
4-pin
[5]
P5 (SOL)
(G)(H)
4-pin (blue)
[6]
P6 (YPM)
(G)(H)
Pulse motor, X
4-pin
[7]
P7 (XPM)
(G)(H)
Operation panel
26-pin
None
P8 (PANEL)
None
Upper shaft motor
3-pin
None
P11 (UVW)
(A)(B)(C)(D)(E)(F)
Presser solenoid
Thread trimmer solenoid
Pulse motor, Y
(G)
9. Secure the cord bundle (1) with the cord clamps (12) and (13).
10. Close the cord presser plate (6) in the direction of the black arrow, and secure it by tightening the screws (5).
Note:
Check that the cords do not get pulled when the machine head is tilted back gently.
11. Tighten the cover (main P.C. board mounting plate (4)) with the six screws (3).
Note:
Check that the cords do not come into contact with the fan (14) and that they are not clamped by the cover at this time.
Note:
Check that the main PROM (15) is version MN-G or later.
BE-438C
13
3. INSTALLATION
3-13. Installing the belt cover
1. Loosen the screw (2) of the upper cover (1).
2. Insert the belt cover (3) in the direction of the arrow, and
then secure it with the screw (2) and the two screws (4).
Check that the cords do not get clamped by the belt cover
at this time.
* It is not necessary to remove the belt cover (3) when
tilting back the machine head.
2456Q
3-14. Installing the foot switch
2507Q
[A]
[B]
2508Q
2506Q
1. Insert the connector of the foot switch (3) into the connector (2) of the control box (1).
2. Install the foot switch (3) to the work table leg (12) with foot switch support plate A (4), foot switch support plate C (5), the
bolt (6), spring washer (7), flat washer (8), bolt (9), spring washer (10) and flat washer (11) as shown in Figure A.
If foot switch support plate B (13) is used in a back-to-front position, it can be used as shown in Figure. B.
1. Remove the screw (14) and rubber plug (15).
* Note that the spring (16) will come out when the screw (14) is removed.
2. Turn foot switch support plate B (13) back to front, and then install it with the bolt (17), spring washer (18) and flat washer
(19) as shown in Figure. B.
Note:
If using the foot switch without installing it to the work table leg, move the foot switch at least 10 mm away from the leg. If
the foot switch is not fully in contact with the work table leg when the foot switch is used, for example, if it is just hooked
loosely onto the work table leg, it may cause the sewing machine to operate incorrectly.
If using the optional two-pedal foot switch, change the setting of DIP switch A on the oreration panel while referring to
"Setting the presser mode" on page 45.
14
BE-438C
3. INSTALLATION
3-15. Installing the spool stand
Assemble the spool stand (1) while referring to the spool
stand instruction manual, and then install the spool stand (1)
at the right side of the work table.
2509Q
3-16. Installing the button tray
1. Install the button tray holder (1) with the two flat wood
screws (2) at a place convenient for operation.
2. Insert the button tray (3) into the button tray holder (1),
and secure them with the screw (4).
2652Q
CAUTION
Attach all safety devices before using the sewing machine.
If the machine is used without these devices attached, injury may result.
3-17. Installing the eye guard
Install the eye guard assy (2) to the face plate (1) with the
two screws (3).
2510Q
BE-438C
15
4. LUBRICATION
4. LUBRICATION
CAUTION
Turn off the power switch before starting lubricating, otherwise the machine may operate if the foot switch is
depressed by mistake, which could result in injury.
Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get
into your eyes or onto your skin, otherwise inflammation can result.
Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and
diarrhoea.
Keep the oil out of the reach of children.
Note 1: Fill the machine with oil when the oil level is down to about one-third full in the oil sight glass.
If oil is not added and the oil drops below this level, there is the danger that the machine may seize during operation.
Note 2: Be sure to let the machine operate for a while after adding the oil.
Note 3: If there is no more oil on the felt of the shuttle race base, problems with sewing may result, so add oil to the felt until it
is slightly soaked.
Note 4: Use only specified Brother oil (Nisseki Mitsubishi Sewing Lube 10N;VG10) for the machine oil.
4-1. Lubrication points
2458Q
1. Fill the arm-side oil tank with oil.
0078Q
2. Fill the bed-side oil tank with oil
2513Q
2512Q
3. Add oil to the felt (1) of the shuttle race base.
* When setting up the sewing machine and when it
hasn’t been used for an extended period of time, be
sure to add 2-3 drops oil to the felt.
16
4. If using the liquid cooling tank (2), fill it with silicon oil
(100 mm2/s).
BE-438C
5. OPERATION
5. OPERATION
5-1. Name and function of each operation panel item
2514Q
(1) POWER indicator ................. Illuminates when the power switch has been turned on.
(2) RESET switch ...................... Press this switch to reset the machine when an error occurs.
(3) TEST switch........................ Use this switch when you want to operate only the feed mechanism in order to check a
pattern.
(4) TEST indicator ..................... Illuminates when the TEST switch has been pressed.
(5) BOBBIN. WIND switch ......... Press this switch to wind the lower thread.
(6) SELECT switch ................... Use this switch to select a menu (program number, X and Y feed, speed and counter).
Each time the switch is pressed, one of the menu indicators ((7) to (11)) illuminates, and the
setting for that menu item appears in the display (14).
The illuminated indicator changes as follows each time the switch is pressed.
PROGRAM NO. indicator (7)→X-SCALE indicator (8)→‚x
-SCALE indicator (9)→SPEED indicator (10)→COUNTER indicator(11)
(7) PROGRAM NO. indicator..... Illuminates when the SELECT switch (6) is pressed to shown the program number setting.
BE-438C
17
5. OPERATION
2515Q
(8) X-SCALE indicator .............. Illuminates when the SELECT switch (6) is pressed to shown the X-scale setting.
(9) Y-SCALE indicator .............. Illuminates when the SELECT switch (6) is pressed to shown the Y-scale setting.
(10) SPEED indicator ................. Illuminates when the SELECT switch (6) is pressed to shown the speed setting.
(11) COUNTER indicator............ Illuminates when the SELECT switch (6) is pressed to show the bobbin thread or
production counter setting.
(12) DISPLAY SET switches ...... Used to change the menu details which are displayed in the window (14).
(13) User program switches ....... Used to set and select user programs.
(14) Display window ................... This display window will indicate the current statu for the selected menu, error or memory
switch.
18
BE-438C
5. OPERATION
5-2. Operating procedure
Preparation
Turn on the power switch.
* The POWER indicator (1) will illuminate and the
program number will flash in the display window (14).
Program No.
X-scale (%)
Y-scale (%)
Speed (rpm)
Factory default
0*
100
100
2,000
Variable range
1 - 49
20 - 200
20 - 200
1,000 - 2,500
* For checking the origin points for X and Y feed
Note when creating additional data
When sewing data with a small number of stitches (15 stitches or less) is sewn repeatedly (short cycle operation), the
upper shaft motor may overheat and the “E-20” error code may be generated.
5-2-1. Setting the program number
Determine the appropriate program from the program list which is given on pp. 3 - 5.
1
Press the SELECT switch (6)
until the PROGRAM NO. indicator illuminates.
2
Press the DISPLAY SET
switches (12) until the desired
program number is flashing in
the display window.
3
Depress the foot switch to the
second step.
* The display will stop flashing and
illuminates steadily, and the feed
mechanism will move to the
sewing start position.
0085Q
1st step
2nd step
2516Q
This completes the setting of the program
number.
2517Q
5-2-2. Setting the X-scale and Y-scale
1
Press the SELECT switch (6)
until the X-scale or Y-scale
indicator illuminates.
2
Press the DISPLAY SET
switches (12) until the desired
scale setting is flashing in the
display window.
(The setting is displayed as a percentage.)
3
Depress the foot switch to the
second step.
* The display will stop flashing and
illuminates steadily, and the feed
mechanism will move to the
sewing start position.
0085Q
1st step
2nd step
2518Q
This completes the setting of the X-scale or
Y-scale.
2519Q
Note:
Be sure to check the sewing pattern (refer to page 21) after setting has been completed to make sure that the needle
drops down into the hole of the botton.
BE-438C
19
5. OPERATION
5-2-3. Setting the sewing speed
1
Press the SELECT switch (6)
until the SPEED indicator illuminates.
2520Q
2
Press the DISPLAY SET
switches (12) until the desired
speed setting is flashing in the
display window.
2603Q
Note:
Be sure to check the sewing pattern (refer to page 21) after setting has been completed to make sure that the needle
drops down into the hole of the botton.
20
BE-438C
6. CHECKING THE SEWING PATTERN
6. CHECKING THE SEWING PATTERN
When checking by operating only the feed mechanism
2. Set the X-scale and Y-scale in accordance with the
hole pitch of the buttons being used.
1. Turn on the power switch.
The POWER indicator will illuminate and the program
number will flash in the display window.
(Refer to “5-2-2. Setting the X-scale and Y-scale”.)
4. Press the TEST switch.
(The TEST indicator will illuminate.)
0090Q
3. Set the button. (Refer to “7-7. Inserting the button”.)
5. Depress the foot switch to the second step.
* For two-pedal foot switch, lower the work clamp before depressing the start switch (right side).
(The feed mechanism will move to the sewing start position and the program number will stop
flashing.)
* This operation is only carried out the first time that a program has been selected or the size ratio
has been changed.
1st step
2nd step
0085Q
0085Q
6. Depress the foot switch to the second step.
Only the feed mechanism will move.
1st step
2nd step
The feed mechanism moves forward by one stitch each time the foot switch is depressed.
Each time the feed mechanism is moved forward by one stitch, turn the machine pulley by
hand and check that the needle goes into the holes in the button without touching the button.
Do this for each hole position. (Note)
After checking is complete, depress the foot switch to move the feed mechanism to the end
position.
* If you depress the foot switch again and keep it depresses after the feed mechanism has
started to move, the feeding speed will increase.
* If you would like to stop the feed while it is moving, press the TEST switch.
0384Q
7. Press the TEST switch.
(The TEST indicator will switch off and the test mode will be cleared.)
0092Q
0093Q
8. Depress the foot switch.
The work clamp will rise and the preparation for sewing will be completed.
Note: If the needle touches the button, carry out the following.
1. Check that the needle size correctly matches the diameter of the holes in the button. (Refer to “7-1. Selecting the
needle and thread”.)
2. Make fine adjustments to the X-scale and Y-scale. (Refer to “5-2-2. Setting the X-scale and Y-scale”.)
3. Adjust the position of the button holder. (Refer to “10-10. Adjusting the position of the button holder”.)
To ensure safety during use ......
You can prevent accidental changes being made to
programs by setting DIP switches 7 and 8 to ON.
When DIP switch 7 is ON
... The sewing pattern cannot be enlarged.
When DIP switch 8 is ON
... The program number cannot be changed.
2459Q
BE-438C
21
7. CORRECT USE
7. CORRECT USE
7-1. Selecting the needle and thread
Needle
Refer to the table at right for details on which needle and
thread to select.
Note: Use buttons which have a hole diameter that is
greater than the value given in the table, to ensure
that the needle does not touch the button.
Thread
TQ × 1 #11
TQ × 1 #12
TQ × 1 #14
#60
#50
Button hole diameter
1.5mm or greater
1.6mm or greater
1.7mm or greater
7-2. Installing the needle
CAUTION
Turn off the power switch before installing the
needle, otherwise the machine may operate if the
foot switch is depressed by mistake, which could
result in injury.
Loosen the set screw (1), insert the needle (2) as far as it
will go so that the groove is facing toward you, and then
tighten the set screw (1).
2653Q
7-3. Threading the upper thread
CAUTION
Turn off the power switch before threading the thread, otherwise the machine may operate if the foot switch is
depressed by mistake, which could result in injury.
Thread the upper thread correctly as shown in the illustration below.
* If the tension release lever (1) is raised in the direction of the arrow, it will be easier to open the tension disc (2) and pull the
thread through.
0386Q
2654Q
[When using the liquid cooling tank]
Approx.40mm
0102Q
0387Q
22
BE-438C
7. CORRECT USE
7-4. Winding the lower thread
CAUTION
Do not touch any of the moving parts or press any objects against the machine while winding the lower thread, as this
may result in personal injury or damage to the machine.
1. Place the bobbin all the way onto the shaft.
2. Thread the thread as shown in the illustration at
right, wind the thread around the bobbin several
times in the direction of the arrow, and then
press the bobbin presser (1).
3. Turn on the power switch.
(The POWER indicator on the operation panel will
illuminate.)
2527Q
4. Depress the foot switch (2) to move the feed mechanism to the sewing start.
2528Q
5. Check that the button is not inserted and the needle does not touch the button
clamp, and then while pressing the BOBBIN. WIND switch (3), depress the foot
switch (2) to start the machine. Keep depressing the foot switch (2) until the
lower thread stops being wound onto the bobbin.
Release the BOBBIN. WIND switch (3) after the machine starts operating. If you release the
foot switch before winding is completed, depress it once more while pressing and holding the
BOBBIN. WIND switch (3).
2529Q
6. The bobbin presser (1) will automatically return to its original position after a set amount of thread (80 - 90% of
the bobbin capacity) has been wound on.
7. Release the foot switch (2).
8. Remove the bobbin,
hook the thread onto
the knife (4), and then
pull the bobbin in the
direction of the arrow
to cut the thread.
9. To wind more thread
onto the bobbin, loosen
the set screw (5) and
pull the bobbin presser
(1) outward.
2530Q
2531Q
<<If the thread winds onto the bobbin unevenly>>
If the thread winds onto the bobbin unevenly, loosen
the nut (6) and turn the bobbin winder thread tension
stud (7) to adjust.
* If the thread winds on as shown in A, turn the bobbin
winder thread tension stud (7) clockwise; if it winds on
as shown in B, turn the bobbin winder thread tension
stud (7) counterclockwise.
Case A
Case B
2532Q
BE-438C
23
7. CORRECT USE
7-5. Replacing the bobbin case and threading the thread
CAUTION
Turn off the power switch before removing or inserting the bobbin case, otherwise the machine may operate if the
foot switch is depressed by mistake, which could result in injury.
2610Q
2534Q
30mm
2535Q
1. Pull the shuttle race cover (1) toward you to open it.
2. Insert a new bobbin into the bobbin case, and then pass the thread through the slot (2) and pull it out from the thread hole
(3). Check that the bobbin turns in the direction of the arrow when the thread is pulled at this time.
3. Pass the thread through the lever thread hole (4), and then pull out approximately 30 mm of thread.
7-6. Thread tension
7-6-1. Thread tension reference guide
Thread
#60 or equivalent
Thread take-up spring tension
(mm)
0.4 - 0.6
Upper thread tension (N)
0.7 - 1.3
Pre-tension (N)
0.1 - 0.3
Lower thread tension (N)
0.3 - 0.4
Needle
TQ × 1 #12
Thread take-up spring height
(mm)
9 - 11
24
BE-438C
7. CORRECT USE
7-6-2. Lower thread tension
Adjust the thread tension to the weakest possible tension by
turning the thread tension nut (1) until the bobbin case will
not drop by its own weight while the thread end coming out
of the bobbin case is held.
Weaker Stronger
2536Q
7-6-3. Upper thread tension
Turn the tension nut (1) (main tension) to adjust the tension
as appropriate for the material being sewn.
Furthermore, turn the thread nut (2) (sub-tension) to adjust
the remaining length of upper thread to 35 - 40 mm when the
thread take-up lever is not used.
Weaker
Stronger
.
Weaker
Stronger
2655Q
7-6-4. Thread take-up spring height
Loosen the set screw (1) and turn the tensioner body to
adjust the thread take-up spring height.
Lower
Higher
2656Q
BE-438C
25
7. CORRECT USE
7-6-5. Thread take-up spring tension
Turn the tension stud (1) with a screwdriver.
Stronger
Weaker
2657Q
7-6-6. Adjusting arm thread guide R
The standard position of arm thread guide R (1) is when the
screw (2) is aligned with mark .
To adjust the position, loosen the screw (2) and then move
arm thread guide R(1).
* When sewing thick material, move arm thread guide R(1)
to the left. (The thread take-up amount will become
greater.)
* When sewing thin material, move arm thread guide R(1)
to the right. (The thread take-up amount will become
less.)
Become
greater
Become less
.
2658Q
7-6-7. Thread take-up amount
Loosen the screw (1) and move the stopper (3.57 nut) (2) to
adjust the operating angle of the thread take-up solenoid (3).
* To reduce the thread take-up amount, move the stopper
(2) upward.
* To increase the thread take-up amount, move the stopper
(2) downward.
Become less
Become greater
2541Q
26
BE-438C
7. CORRECT USE
7-7. Inserting the button
1. Press the cam plate (1) to open the button holder (2).
2. Insert the button, making sure that the button is facing
the directing shown in the illustration, then release the
cam plate (1).
2659Q
7-8. Adjusting the button holder
1. Insert the button in the button holder. Confirm that the
button is securely held by the holder.
2. Loosen the set screw (1), while the button is held by the
holder. Move the adjusting plate (2) so that the space
between the adjusting plate (2) and screw (3) is
approximately 0.5 - 1.0 mm, then tighten the set screw
(1).
0.5 - 1.0mm
2660Q
7-9. Adjustment by the accessory spring
If you would like the button to be raised up more after it is
sewn, install the accessory spring.
1. Install the spring support (1) with the bolt (2).
2. Install the spring (3) with the washer (4) and the screw
(5).
2661Q
BE-438C
27
7. CORRECT USE
7-10. Replacing the PROM
DANGER
Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before
opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury.
2542Q
2461Q
2544Q
2543Q
2545Q
1. Turn off the power switch.
2. Remove the six screws (1), and then open the control box cover (main P.C. board mounting plate (2)).
Note: When opening the cover, hold it securely so that it does not fall down.
3. Use the special tool to remove the PROM control assembly (3) from the PROM socket (4).
Store the removed PROM control assembly in the special case provided.
4. Bend the pins of the PROM control assembly which is to be installed (5) so that they are at an angle of approximately 90°.
5. Make the directions of the PROM control assembly (5) and the PROM socket (4) same so that the portions (a) come on the
same side, and press the PROM gently into the socket while checking that the pins of the PROM are going into the socket
properly.
6. While pressing the RESET switch (6), turn on the power switch to initialize the memory.
Note: All of the user programs, cycle programs and memory switches which have been recorded will then be cleared.
.
28
BE-438C
8. SEWING
8. SEWING
CAUTION
Turn off the power switch at the following times, otherwise the machine may operate if the foot switch is depressed
by mistake, which could result in injury.
• When threading the needle
• When replacing the needle and bobbin
• When not using the machine and when leaving the machine unattended.
Do not touch any of the moving parts or press any objects against the machine while sewing, as this may result in
personal injury or damage to the machine.
Before starting sewing ......
• Check that the needle bar is at its highest position. Turn the
machine pulley so that the index mark (1) on the pulley is
between the marks (2) on the belt cover.
* If the machine pulley stop position is incorrect, error “E50” may be displayed, or the wiper may come into contact
with the needle and break the tip of the needle.
2462Q
1. Turn on the power switch.
(The POWER indicator will illuminate and the program number will flash in the display.)
2. Depress the foot switch to the 2nd step.
The feed mechanism will move to the starting position and
the button clamp will rise.
* Note that if the foot switch is pressed to the 2nd step
while the program number is illuminated, the machine will
start operating.
1st step
2nd step
0085Q
3. Insert the button to the button holder. (Refer to “7-7. Inserting the button”.)
4. Place the material to be sewn under the button clamp,
and then depress the foot switch.
When the foot switch is pressed to the 1st step, the button
clamp will lower.
If you would like to shift the position of the material, release
the foot switch. The button clamp will then rise again.
When the foot switch is pressed to the 2nd step, the
machine will start operating.
* When sewing programs which do not use crossover
stitches (program Nos. 14, 15, 20, 22, 28, 29, 32, 33, 35),
press the foot switch twice, or keep pressing it until the
second sewing operation starts.
0395Q
5. Once sewing is completed and the thread has been trimmed, the button clamp will rise.
BE-438C
29
9. MAINTENANCE AND INSPECTION
9. MAINTENANCE AND INSPECTION
CAUTION
Turn off the power switch before carrying out cleaning, otherwise the machine may operate if the foot switch is
pressed by mistake, which could result in injury.
Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get
into your eyes or onto your skin, otherwise inflammation can result.
Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and
diarrhoea. Keep the oil out of the reach of children.
Wait until the motor has cooled down before cleaning the air holes.
The motor may be hot immediately after it has been used, and it may cause burns if touched.
9-1. Checking the needle
Always check that the tip of the needle is not broken and
also the needle is not bent before starting sewing.
0121Q
9-2. Cleaning the rotary hook
0122Q
1. Pull the shuttle race cover toward you to open it, and then
remove the bobbin case.
2. Open the setting claw (1) in the direction indicated by the
arrow, and then remove the shuttle race body (2) and the
shuttle hook (3).
2548Q
3. Clean all the dust and thread ends from around the driver
(4), the top of the rotary hook thread guide and the shuttle
race.
2549Q
30
BE-438C
9. MAINTENANCE AND INSPECTION
9-3. Lubrication
Note 1: Fill the machine with oil when the oil level is down to about one-third full in the oil sight glass.
If oil is not added and the oil drops below this level, there is the danger that the machine may seize during operation.
Note 2: Be sure to let the machine operate for a while after adding the oil.
Note 3: If there is no more oil on the felt of the shuttle race base, problems with sewing may result, so add oil to the felt until it
is slightly soaked.
Note 4: Use only specified Brother oil (Nisseki Mitsubishi Sewing Lube 10N;VG10) for the machine oil.
2458Q
1. Fill the arm-side oil tank with oil.
2. Fill the bed-side oil tank with oil.
0078Q
3. Add oil to the felt (1) of the shuttle race base.
* When setting up the sewing machine and when it
hasn’t been used for an extended period of time, be
sure to add 2-3 drops oil to the felt.
2512Q
4. If using the liquid cooling tank (2), fill it with silicon oil (100
mm2/s).
2513Q
BE-438C
31
9. MAINTENANCE AND INSPECTION
9-4. Draining the oil
1. Remove and empty the waste oil container (1) whenever
it is full.
2. After emptying the waste oil container (1), screw it back
into its original position.
2550Q
9-5. Cleaning the control box air inlet port
Use a vacuum cleaner to clean the filter in the air inlet port
(2) of the control box (1) at least once a month.
* If the machine is used while the air inlet port is blocked,
the inside of the control box will overheat.
When this happens, the overheating error code (“E-d0”)
will be displayed and you will not be able to operate the
sewing machine.
2551Q
9-6. Cleaning the air holes of belt cover and frame side cover
Remove the belt cover (1) and the frame side cover (2), and
then clean the air holes (3).
After cleaning, install the belt cover (1) and the frame side
cover (2).
* If dust collects in the air holes, it may cause the motor to
overheat. The air holes should be cleaned at regular
intervals.
In addition, be careful not to let any foreign matter get into
the air holes.
2463Q
9-7. Cleaning the eye guard
Wipe the eye guard clean with a soft cloth.
Note:
Do not use solvents such as kerosene or thinner to clean
the eye guard.
0128Q
32
BE-438C
10. STANDARD ADJUSTMENTS
10. STANDARD ADJUSTMENTS
CAUTION
Maintenance and inspection of the sewing machine
should only be carried out by a qualified technician.
Ask your Brother dealer or a qualified electrician to
carry out any maintenance and inspection of the
electrical system.
Turn off the power switch and disconnect the power
cord from the wall outlet at the following times,
otherwise the machine may operate if the foot switch
is depressed by mistake, which could result in injury.
• When carring out inspection, adjustment and
maintenance
• When replacing consumable parts such as the
rotary hook and knife
Hold the machine head with both hands when tilting it
back or returning it to its original position.
Furthermore, after tilting back the machine head, do
not push the face plate side or the pulley side from
above, as this could cause the machine head to
topple over, which may result in personal injury or
damage to the machine.
If the power switch needs to be left on when carrying
out some adjustment, be extremely careful to observe
all safety precautions.
If any safety devices have been removed, be
absolutely sure to re-install them to their original
positions and check that they operate correctly before
using the machine.
10-1. Adjusting the needle bar height
2663Q
2553Q
Turn the machine pulley to move the needle bar to the lowest position. Then remove the rubber plug (2), loosen the set screw
(3) and then move the needle bar up or down to adjust so that the highest reference line (reference line A ) is aligned with the
lower edge of the needle bar bush (1).
10-2. Adjusting the needle bar lift amount
2664Q
2464Q
Turn the machine pulley to raise the needle bar from the lowest position until the second reference line from the top of the
needle (reference line B) is aligned with the lower edge of the needle bar bush (1). Then loosen the screw (2) and move the
driver (3) to adjust so that the tip of the rotary hook is aligned with the needle center line.
BE-438C
33
10. STANDARD ADJUSTMENTS
10-3. Adjusting the driver needle guard
Needle center line
Tip
0135Q
2555Q
2556Q
Turn the machine pulley to align the tip of the rotary hook with the needle center line. Then loosen the set screw (2) and turn
the eccentric shaft (3) to adjust so that the driver needle guard (1) contacts the needle.
If the needle contact pressure is too great, skipped stitches may occur. On the other hand, if the driver needle guard (1) is not
touching the needle, the tip of the inner rotary hook will obstruct the needle, resulting in an excessively high amount of friction.
10-4. Adjusting the needle clearance
0.01 - 0.08mm
0138Q
2557Q
Turn the machine pulley to align the tip of the rotary hook with the needle center line. Then loosen the set screw (1) and turn
the eccentric shaft (2) to adjust so that the clearance between the needle and the rotary hook is 0.01 - 0.08 mm.
10-5. Adjusting the shuttle race thread guide
2558Q
Install the shuttle race thread guide (1) by pushing it in the direction of the arrow so that the needle groove is aligned with the
center of the needle plate hole.
Note:
If the shuttle race thread guide is in the wrong position, thread breakages, soiled thread or catching of the thread may
occur.
The position of the shuttle race thread guide is adjusted at the time of shipment from the factory. It should not be changed if
at all possible.
34
BE-438C
10. STANDARD ADJUSTMENTS
10-6. Adjusting the thread take-up amount
Thread take-up amount (stroke)
Become less
Become greater
2559Q
2560Q
At the time of shipment from the factory, the thread take-up amount (stroke) of the thread take-up lever (1) is set to the
standard setting of 5 mm. You may need to adjust this setting depending on the sewing conditions to prevent the thread from
pulling out at the sewing start.
[Adjustment method]
Loosen the screw (2) and move the stopper (3.57 nut) (3) to adjust the operating angle of the thread take-up solenoid (4).
* To reduce the thread take-up amount, move the stopper (3) upward.
* To increase the thread take-up amount, move the stopper (3) downward.
Note:
Do not increase the stroke of the thread take-up lever any more than is necessary.
If the sub-thread tension is too high, the needle thread length may become too short and the thread may come out of the
needle. Furthermore, if the sub-thread tension is too weak, the needle thread length may become too long and the
underside of the article being sewn may become untidy.
BE-438C
35
10. STANDARD ADJUSTMENTS
10-7. Adjusting the movable knife
Mark
2561Q
2465Q
1. Remove the top cover (1) while making this adjustment.
2. Press down on the plunger (2) of the thread trimming solenoid as shown in the illustration, and fit the roller (3) into the
groove of the thread trimmer cam (4).
3. In this condition, turn the machine pulley to align the position of the roller (3) with the mark on the thread trimmer cam (4)
2563Q
2562Q
4. Loosen the nut (6) and move the connecting rod lever (7) to the left or right to adjust so that the V section A is aligned with
the index mark B on the needle plate when in this condition (the procedure 3.) and the movable knife (5) is pushed to the
machine pulley side so that there is no play.
36
BE-438C
10. STANDARD ADJUSTMENTS
10-7-1. Replacing the movable knife and fixed knife
2466Q
2665Q
1. Open the large shuttle hook cover, remove the screws (1) and (2), and then remove the feed plate (3).
2. Remove the two screws (4) and the two screws (5), and then remove the needle plate (6).
3. Remove the thread trimmer connecting rod (7) from the connecting rod lever pin (8).
2944Q
2945Q
4. Remove the movable knife (9) and replace it with a new one. At this time, check that the movable knife (9) and the fixed
knife (10) cut the thread cleanly. If necessary, adjust by using the appropriate movable knife washer (11) (supplied as
accessories).
* Apply grease to the outside of the collar (12) at this time.
5. Install the fixed knife (10) at a distance of 0.5 mm from the needle hole plate (13).
6. Place the thread trimming connecting rod (7) onto the connecting rod lever pin (8), and then install to the needle plate (6).
.
BE-438C
37
10. STANDARD ADJUSTMENTS
10-7-2. Adjusting the engagement of the movable knife and fixed knife
0149Q
Fig. 1
Movable knife
Fixed knife
Cutting
edge
Cutting
edge
Cutting
edge
Cutting
edge
2949Q
0150Q
A. After the movable knife and fixed knife are properly engaged, tighten the screw as shown in Fig. 1.
B. Turn the movable knife (in the direction of the arrow) while the screw is still tightened.
C. Loosen the screw.
D. Turn the movable knife (in the direction of the arrow) while the screw is still loosened.
Repeat above steps A, B, C and D four or five times to maintain the cutting performance of the knife.
10-8. Adjusting the button clamp lift amount
The maximum button clamp lift amount is 13 mm from the top of the needle plate.
(The lift amount is adjusted 10 - 11 mm at the time of shipment.)
2666Q
Remove the button clamp presser spring (1), loosen the screw (2) and adjust the button clamp holder hook (3) by moving it
up and down.
* If the button clamp lift amount is too large, the button clamp will not be raised.
* If the button clamp cannot be raised or lowered, error code “E-61” or “E-63” will be displayed.
38
BE-438C
10. STANDARD ADJUSTMENTS
10-9. Adjusting the holding pressure
Loosen the adjusting nut (1) and turn the adjusting nut (2) to
the point where it is just tight enough that the material will not
slip out of place when it is slightly pulled (keep pressure as
slight as possible).
2667Q
10-10. Adjusting the position of the button holder
1. Loosen the two hexagonal bolts (1) and adjust the button
holder body (2) by moving it.
2. Check that the needle will go through the button hole with
no contact. (Refer to “6. CHECKING THE SEWING
PATTERN”.)
2668Q
BE-438C
39
10. STANDARD ADJUSTMENTS
10-11. Adjusting the needle up stop position
The needle up stop position is adjusted so that the index
mark (2) on the machine pulley (1) is inside the mark (4) on
the belt cover (3).
If adjustment is necessary, loosen the screw (5) at the “U”
mark of the machine pulley (1) and adjust the position of the
machine pulley (1). The machine pulley (1) stops later if it is
turned clockwise, and it stops earlier if it is turned
counterclockwise.
Note:
The screw (6) at the “D” mark is an adjusting screw for
the needle down detection function and is adjusted to
match the feed timing, so it should not be loosened.
The screw (7) is a screw for detecting the machine stop
position, and should not be loosened.
* If the index mark (2) is not inside the mark (4) when the
sewing machine is started, error code “E-50” will be
displayed. Turn the machine pulley to move the index
mark (2) to the correct position and then start the sewing
machine.
2576Q
10-12. Adjusting the thread wiper
2578Q
2580Q
2 ± 0.5mm
Approx.
20mm
2579Q
2577Q
1. Loosen the set screw (2) and move the wiper arm support (3) up or down to adjust so that the clearance between the top of
the thread wiper and the needle point (1) is 2 ± 0.5 mm when the thread wiper is aligned with the center of the needle.
* Before carrying out this adjustment, check that the needle bar is lowered 3.5 to 4 mm from the needle up stop position
when the sewing machine stops.
2. Loosen the screw (4) and move the thread guide connecting plate (5) up or down so that the thread wiper is approximately
20 mm from the needle when it is at the standby position.
40
BE-438C
10. STANDARD ADJUSTMENTS
10-13. Checking the input sensor and DIP switch input
2581Q
1. When the X-SCALE indicator (1) is illuminated and the RESET switch (3) is pressed while the TEST switch (2) is being
pressed, the state of the X home position signal will appear on the display window (4).
• When sensor is ON
• When sensor is OFF
2. Each time the SELECT switch (5) is pressed, a different indicator will illuminate and the operating condition for the
corresponding item will appear on the display window (4).
• When X-SCALE indicator is illuminated................. X home position sensor (ON when home position detected)
• When Y-SCALE indicator is illuminated ................. Y home position sensor (ON when home position detected)
• When SPEED indicator is illuminated .................... Synchronizer ( * 1)
• When COUNTER indicator is illuminated .............. Presser sensor (ON when presser is lowered)
*1 The synchronizer display simultaneously displays the needle up signal (3rd digit), the 24-section signal (2nd digit) and
the needle down signal (1st digit).
[ H L L]
“H” when the sensor is on, and “L” when the sensor is off
Needle down signal
24-section signal
Needle up signal
If the DIP switches at the side of the operation panel are changed at this time, the number of the DIP switch which was
changed will be displayed in the 4th digit position of the display window (4) for about one second.
Note:
The DIP switch can be changed at this time without turning off the power so that you can check the DIP switch input.
However, you should normally always turn off the power when changing DIP switch settings.
3. Press the TEST switch (2) again to return the display to the normal condition.
BE-438C
41
10. STANDARD ADJUSTMENTS
10-14. Checking the input voltage
2582Q
Specifications
Display
200V
[090 - 110]
220V
[100 - 120]
230V
[105 - 125]
100V
380V
400V
415V
[100 - 120]
Notes
“100” is displayed when the input voltage is 200 V.
“110” is displayed when the input voltage is
100V (for 100-V specs.), 380V (for 380-V specs.),
400V (for 400-V specs.) or 415V (for 415-V specs.).
1.
2.
3.
4.
Turn on the power switch.
Press the SELECT switch (1) until the Y-SCALE indicator (2) illuminates.
While pressing the TEST switch (3), press the RESET switch (4).
If the input voltage is normal, the input voltage conditions will be shown in the display window (5) as indicated in the table
above.
5. Press the TEST switch (3) again to return the display to the normal condition.
10-15. Clearing all memory settings
If the sewing machine stops operating normally, the cause may be that an incorrect memory setting may have been made by
means of the memory switch, for instance. In such cases, carry out the following procedure to clear the memory, and also
check the DIP switch settings.
[ Method ]
While pressing the RESET switch, turn on the power. This will clear all of the memory setting.
Note
• This operation causes memory switches to be returned to their initial settings, and user program settings to be cleared.
• If the optional emergency stop switch has been installed, you should reset memory switch No. 10 to ON.
42
BE-438C
10. STANDARD ADJUSTMENTS
10-16. Moving stitch patterns
• Programs which have already been programmed can be moved up, down and to the left and right.
* Once the power switch has been turned off, the amount of movement that has been stored in memory is reset. However,
if memory switch memo-28 is set to ON, you can keep the amount of movement recorded in memory. (The amount of
movement is retained in memory even when the power switch is turned off.)
* The amount of movement is reset when you change the program number.
• The feed position can be set to the any position desired.
2583Q
1. Select the program number, and then press the start switch once to move the feed mechanism to the sewing start position.
2. Press the SELECT switch (1) until the PROGRAM NO. indicator (2) illuminates.
3. While pressing the TEST switch (3), press the RESET switch (4).
> will appear in the display window (6).
* The TEST indicator (5) will illuminate and <
4. Press the SELECT switch (1) so that either the X-SCALE indicator (7) or Y-SCALE indicator (8) illuminates.
5. Press the DISPLAY SET switches (9) to move the feed mechanism one pulse at a time.
• If the DISPLAY SET ( ) switch is pressed while the X-SCALE indicator is illuminated, the feed mechanism will move to
the left.
• If the DISPLAY SET ( ) switch is pressed while the X-SCALE indicator is illuminated, the feed mechanism will move to
the right.
• If the DISPLAY SET ( ) switch is pressed while the Y-SCALE indicator is illuminated, the feed mechanism will move
down.
• If the DISPLAY SET ( ) switch is pressed while the Y-SCALE indicator is illuminated, the feed mechanism will move up.
6. When the TEST switch (3) is pressed after the above fine adjustments have been made, the TEST indicator (5) and display
window (6) will both switch off and movement of the stitch pattern will be completed.
Note:
When moving the stitch pattern, take the whole of the pattern area into consideration so that no parts extend outside the
sewing area when the pattern is sewn.
* If you would like to set the feed position to a desired position, carry out steps 2. to 6. above while the display window (6)
is flashing. The stitch pattern will not be moved at this time.
BE-438C
43
11. USING THE COUNTERS
11. USING THE COUNTERS
11-1. Using the bobbin thread counter
If you use the bobbin thread counter to set the number of articles which can be sewn with the amount of bobbin thread
available, you can stop the bobbin thread running out in the middle of sewing a pattern.
1. Press the SELECT switch (1) until the COUNTER
indicator (2) illuminates.
2. While pressing the TEST switch (3), press the RESET
switch (4).
* The COUNTER indicator (2) will flash and the counter
will switch to bobbin thread counter setting mode.
3. Press the DISPLAY SET switches (5) to set the number
of articles to be sewn.
• The bobbin thread counter can be set to sew a number
of articles from one (“0001”) through to 9999 (“9999”).
If the bobbin thread counter is set to “0000”, sewing is
carried out without the number of articles sewn being
counted.
• If you press the RESET switch (4) while setting the
bobbin thread counter, the setting will return to “0000”.
4. Press the TEST switch (3).
* The number displayed in the display window (6) will
then be stored as the bobbin thread counter setting.
2584Q
5. Each time the sewing of a single article is completed, the number being displayed in the display window (6) will become
smaller. When the number of articles set by the bobbin thread counter have all been sewn, “0000” will be displayed in the
display window (6), and an alarm will start sounding continuously.
* The sewing machine will not operate during this time, even if the foot switch is depressed.
6. Replace the bobbin, and then press the RESET switch (4).
* The alarm will then stop sounding, and the number which was set in step 3. above will be re-displayed in the display
window (6).
11-2. Using the production counter
The production counter can be displayed in the display window (6) separately from the bobbin thread counter.
1. Press the SELECT switch (1) until the SPEED indicator
(2) illuminates.
2. While pressing the TEST switch (3), press the RESET
switch (4).
* The COUNTER indicator (5) and the SPEED indicator
(2) will illuminate, and the production counter will be
displayed in the display window (6).
• Press the RESET switch (4) to reset the production
counter to “0000”.
• You can also press the DISPLAY SET switches (7) to
set the production counter to the desired value.
3. When the foot switch is depressed, the sewing machine
will start sewing.
4. If you press the TEST switch (3) or the SELECT switch
(1), the display will return to showing the bobbin thread
counter.
.
2585Q
44
BE-438C
12. CHANGING FUNCTIONS USING THE DIP SWITCHES
12. CHANGING FUNCTIONS USING THE DIP SWITCHES
12-1. Operation panel DIP switches
The functions shown in the table below can be changed by
means of these DIP switches (1).
* All DIP switches are set to OFF at the time of shipment.
Note:
Always turn off the power before setting the DIP
switches.
2586Q
Switch
0176Q
Motion when set to ON
DIPA-1
Presser does not automatically lift after sewing is
completed.
DIPA-2
Two-pedal mode is available.
DIPA-3
User program mode is available.
DIPA-4
−
DIPA-5
The presser does not rise automatically when a split is found.
DIPA-6
Displays the enlargement/reduction ratio in millimeter units instead of as a percentage. (After
changing this setting, be sure to carry out the auto-clear operation by referring to page 42.)
DIPA-7
Enlargement of pattern size is not available.
DIPA-8
Program number is fixed.
See “12-2. Setting the presser mode”
12-2. Setting the presser mode
Through the combination of DIP switches A-1 and A-2 on the operation panel, presser motions can be set as follows:
DIPA-1
DIPA-2
Pedal specifications
Raising the presser at the sewing end
−
−
Single pedal
Presser is raised automatically.
ON
−
Single pedal
Presser is raised by pressing the pedal.
−
ON
Two pedals
Presser is raised automatically, then it is lowered by pressing
the pedal.
ON
ON
Two pedals
Presser is kept lifted while the pedal is pressed.
BE-438C
45
12. CHANGING FUNCTIONS USING THE DIP SWITCHES
12-3. DIP switches inside the control box
DANGER
Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet
before opening the face plate of the control box. Touching areas where high voltages are present can result in
severe injury.
The functions can be changed as shown in the table below
by changing the positions of the DIP switches (1).
* All DIP switches are set to OFF at the time of shipment.
Note:
When opening the cover, hold it securely so that it does
not fall down.
2587Q
Switch
Motion when set to ON
DIPB-1
First two stitches are sewn at a low speed of 260 rpm.
DIPB-2
Last two stitches are sewn at a low speed of 260 rpm.
DIPB-3
−
DIPB-4
Last two stitches are sewn at a low speed of 700 rpm.
DIPB-5
First two stitches are sewn at a low speed of 400 rpm.
DIPB-6
Low speed sewing is not performed at the start of sewing.
DIPB-7
The motor operates in reverse when the upper shaft stops, to return the needle bar to close
to its highest position. *Note
DIPB-8
Maximum area for the sewing data is increased.
*Note:
When the motor operates in reverse to raise the needle, the thread take-up will stop at a position which is lower than its
normal stopping position. As a result, the thread take-up will rise slightly at the sewing start, and this may result in the
thread pulling out under certain conditions.
46
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12. CHANGING FUNCTIONS USING THE DIP SWITCHES
12-4. Using user programs
User program ...
It can store sixteen different programs which can include details such as the program number, X scale, Y scale and sewing
speed. If you are sewing certain patterns over and over again, it is useful to record the settings for these patterns into a user
program.
2588Q
Recording a user program
1. Turn off the power switch and then set DIP switch
A-3 of the DIP switches (1) to ON.
2. Turn on the power switch.
While pressing the TEST switch (2), press the
SELECT switch (3).
* All of the menu indicators ((4) to (8)) will illuminate and the
mode will switch to recording mode.
* In addition, “PP 1” will appear in the display window (9) to
indicate that user program No.1 is being recorded. (Once
recording of No.1 is completed, No.2 will be displayed; once
No.2 is completed, No.3 will be displayed. Thus the next
unrecorded program letter is always displayed.)
3. Press the SELECT switch (3).
* The PROGRAM NO. indicator (4) will illuminate.
2589Q
4. Press the DISPLAY SET switches (10) to select the number for the program that you would like to record.
5. Press the SELECT switch (3). * The X-SCALE indicator (5) will illuminate.
6. Press the DISPLAY SET swithes (10) to select the X scale setting that you would like to record.
7. Press the SELECT switch (3). * The Y-SCALE indicator (6) will illuminate.
8. Press the DISPLAY SET switches (10) to select the Y scale setting that you would like to record.
9. Press the SELECT switch (3). * The SPEED indicator (7) will illuminate.
10. Press the DISPLAY SET switches (10) to select the speed setting that you would like to record.
11.Press the SELECT switch (3). * This completes the recording of user program No.1.
* “PP 2” will then appear in the display window (9), to indicate that user program No.2 is now being recorded.
Repeat steps 3. through to 11. to record further programs as desired.
12. Press the TEST switch (2). This completes the recording.
* The menu indicators ((4) to (8)) will all illuminate and “P1” will appear in the display to indicate that user program No.1 is currently
selected.
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47
12. CHANGING FUNCTIONS USING THE DIP SWITCHES
Using a user program
1. Press the DISPLAY SET switches (10) to select the speed program number for the user program that you would
like to use.
* The user program except P16 can also be selected using the user program switches (11). (See below.)
2. Depress the foot switch to the second step.
3. Check the sewing pattern (see P.21), and then sew the pattern selected.
* P1 to P4 can be selected using the P1 to P4 user program switches (11). P5 to P15 can be selected by pressing the P1 to
P4 switches together in various combinations as shown below.
The switches with solid lines are valid switches for selection.
To select P5
To select P6
To select P7
To select P8
To select P9
To select P11
To select P12
To select P13
To select P14
To select P15
To select P10
0472Q
Clearing the user programs
1. Switch the machine to recording mode by the procedure in steps 2. of recording a user program.
2. Use the DISPLAY SET switches (10) to specify the user program number which is to be cleared of data.
3. Press the RESET switch (12).
* The buzzer will sound and the user program with the number selected will be cleared.
* If you press and hold the RESET switch (12) until after the buzzer has sounded twice, all user programs will be cleared.
Note:
If data has been recorded in user programs P1, P2, P3 and P4 and you then clear the data in user program P2, the
contents of P3 will be transferred to P2, and the contents of P4 will be transferred to P3.
48
BE-438C
13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES
13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES
The functions of the switches on the operation panel (1) can be changed to carry out special functions.
Note:
After changing the memory switch settings, press the power switch to turn the power off and then back on again.
The memory switches “00 - 2F” (except “08”) are set to OFF at the time of shipment.
1. Turn on the power switch.
2. While pressing the TEST switch (2), press the BOBBIN.
WIND switch (3).
* “00 - - ” will appear in the display window (4).
3. Press the DISPLAY SET switches (5) to set the two
digits at the left of the display window (4) to the
corresponding number (00 to 4F) of the function shown
in the table below that you would like to select.
4. When the BOBBIN. WIND switch (3) is pressed, the two
spaces at the right in the display window will change
from “ - - ” to “ON”.
* If you press the RESET switch (6) at this time,
memory switches from 00 to 2F will all be set to OFF
(“--”), and memory switches from 30 to 4F will be
returned to their initial settings.
5. Press the TEST switch (2).
* The display will return to normal.
2590Q
<Memory switches 00 - 0F>
Switch
Motion when set to ON
memo-00
At the end of sewing, the feed plate will be returned to the sewing start point via mechanical home
position.
memo-05
Button clamp will move to the sewing start point, and then will be lifted.
(The button clamp rises at the final stitch to enable the quick taking out of the workpieces.)
Feed will move automatically to the next starting point at the same time as a user program is
switched.
(Normally it moves to the starting point after sewing starts.)
When sewing using programs, the programs which have been set will be sewn in numerical order.
(Cycle sewing mode is set.)
The sewing speed will be fixed at the minimum speed for the maximum pitch of the sewing data.
(Set this to ON if you are concerned that variations in pitch may cause changes in the sewing
speed.)
Increases the presser solenoid lifting force
memo-06
Enlargement and reduction ratio settings for X and Y become the same.
memo-01
memo-02
memo-03
memo-04
memo-07
−
memo-08*
Test feeding is carried out stitch by stitch when the foot switch is depressed.
memo-09
The sewing start point becomes the reference point for enlargements and reductions.
(The reference point for enlargements and reductions is normally the center of the sewing frame.)
memo-0A
−
memo-0b
−
memo-0c
Needle stops in up position during emergency stop.
(EMERGENCY STOP switch is available as an option.)
memo-0d
The bar tacking stitches (with a pitch of less than 1 mm) are also enlarged and reduced.
(Normally stitches with a pitch of less than 1 mm are not enlarged or reduced.)
memo-0E
Test feeding will be performed at the same speed as that for actual sewing.
(This is used for checking feeding operation.)
memo-0F
After sewing is finished, the work clamp automatically opens and closes once (practice operation).
* Set to ON at the time of shipment from the factory, and when all memory settings are initialized.
.
BE-438C
49
13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES
<Memory switches 10 - 1F>
Switch
Motion when set to ON
memo-10
The optional emergency stop switch can be used.
memo-11
On when a two-stage tensioner is used. (Special order device that outputs from option output No. 1)
(Normally the tension opens when output is OFF, and the tension closes when option output No. 1 is
ON)
memo-12
Pneumatic wiper can be used. (Special order device that outputs from option output No. 2)
memo-13
−
memo-14
Solenoid wiper can be used (available as an option).
memo-15
−
memo-16
Needle cooler can be used (available by special order).
memo-17
Thread take-up device is not operated at the sewing end.
memo-18
Thread take-up device operates one stitch before the sewing end.
memo-19
Presser position errors are not detected.
memo-1A
Needle up stop position errors are not detected.
memo-1b
Presser can be moved up and down before the home position is detected.
(Normally the presser cannot be moved up and down until after the home position has been
detected.)
memo-1c
−
memo-1d
−
memo-1E
memo-1F
Errors can be reset using the EMERGENCY STOP switch.
(EMERGENCY STOP switch is available as an option.)
Thread is not trimmed when an emergency stop occurs during sewing.
(EMERGENCY STOP switch is available as an option.)
<Memory switches 20 - 2F>
Switch
memo-20
−
memo-21
Rotating-type thread breakage detector operates. (Device is available by special order.)
memo-22
memo-23
50
Motion when set to ON
During thread breakage detection, sensitivity is decreased from 8 to 14 stitches at the sewing start.
(Sensitivity during sewing is three stitches.)
When DIP switch A-8 is simultaneously ON, setting values changed using the operation panel are
ignored.
memo-24
−
memo-25
−
memo-26
Enables the fiber-type thread breakage detector (when memo-21 is ON)
memo-27
−
memo-28
Stores the amount of parallel movement in memory.
(Use the memory all clear operation to clear the setting.)
memo-29
−
memo-2F
−
BE-438C
13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES
<Memory switches 30 - 4F>
30 to 4F are set by entering two-digit values.
These values are incremented using the P2 switch, and decremented using the P4 switch.
Switch
Possible setting range
Units
Initial value
Explanation
Limits the maximum area in the horizontal
direction (X).
(Limited to 6.4 mm when settings have
been initialized.)
Limits the maximum area in the vertical
direction (Y).
(Limited to 6.4 mm when settings have
been initialized.)
Changes the maximum sewing speed.
memo-30
0 - 30
mm
7
memo-31
0 - 30
mm
7
memo-32
12 - 27
×100rpm
25
memo-33
1 - 15
×7.5°
10
Changes the feed timing
1(Fast) ← 10 (Standard) → 15(Slow)
memo-34
0-5
Stitch
1
The (setting value + 1) number of stitches
are sewn at the speed set by memo-35 at
the sewing start. (No low-speed sewing if
set to 0.)
memo-35
3-9
×100rpm
4
Changes the sewing start speed for the
number of stitches specified by memo-34
memo-36
−
−
−
−
memo-37
1 - 20
×7.5°
10
memo-38
1 - 20
×7.5°
10
memo-39
1 - 20
×7.5°
1
memo-3A
1 - 20
×7.5°
1
memo-3b
1 - 20
×7.5°
1
Changes the feed timing one stitch before the sewing end.
1(Fast) ← 10 (Standard) → 20(Slow)
Changes the feed timing two stitches
before the sewing end.
Changes the feed timing for the third
stitch at the sewing start.
1(Fast) ← 10 (Standard) → 20(Slow)
Changes the feed timing for the second
stitch at the sewing start.
Changes the feed timing for the first stitch
at the sewing start.
memo-3c
0 - 99
Stitch
0
Sets the number of stitches for which the
feed timing (memo-33 setting) is enabled.
0: Enabled for all stitches
1 - 99: Enabled for the specified number
of stitches from the sewing start
memo-3d
−
−
−
−
memo-3E
−
−
−
−
memo-3F
−
−
−
−
memo-40
−
−
−
−
memo-41
−
−
−
−
memo-42
0 - 10
−
0
Changes the work clamp operating
mode. (When set to “0”, the mode is
selected according to the settings for DIP
switches A-1 and A-2.)
memo-43
memo-4F
−
−
−
−
BE-438C
51
13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES
13-1. Using the cycle sewing function
What is the cycle sewing function?
The cycle sewing function lets you program up to four patterns for cycle sewing of patterns in a predeter mined order.
Recording a cycle sewing program
2589Q
1. Set DIP switch (1)-3 to ON, and then record the
patterns which you would like to use for cycle
sewing. (Refer to “12-4. Using user programs”.)
* Cycle sewing cannot be performed using patterns (P1 to P16)
which have not had a user program assigned.
2. Set the memo-03 switch to ON. (Refer to page 49 for
how to do this.)
3. While pressing the TEST switch (2), press the SELECT switch (3).
* All of the menu indicators ((4) to (8)) will illuminate and the
mode will switch to recording mode.
4. Press the P1 switch (9).
• “Pc 1” will appear in the display window (10) to
indicate that cycle sewing program No. 1 is being
recorded.
* Programs P2, P3 and P4 switches can also be used for
programming.
2591Q
5. Press the SELECT switch (3). * The PROGRAM No. indicator (4) will illuminate and “1- -” will appear in the display window (10).
6. Press the DISPLAY SET switches (11) to select the number for the user program that you would like to record.
7. Press the SELECT switch (3). * “2- -” will appear in the display window (10).
8. Press the DISPLAY SET switches (11) to select the number for the user program that you would like to record.
9. Repeat steps 5. and 6. to record all programs which you would like to include for cycle sewing.
*
*
After “9- -” is displayed, “A- -”, “b- -”, “c- -”, “d- -”, “E- -” and “F- -” will be displayed in that order so that up to the 15th pattern can be
recorded.
If you would like to return to a previous number during the recording procedure, press the P1 switch so that “Pc 1” is displayed, and then
return to step 4.
10. Press the TEST switch (2).
• This completes the setting of cycle sewing program No. 1.
*
52
The menu indicators ((4) to (8)) will all illuminate and “c1-1” will appear in the display window (10) to indicate that the cycle sewing
program No.1 is currently selected.
BE-438C
13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES
Using a cycle sewing program
1. When “c1-1” is flashing in the display window (10), press the foot switch to the second step.
2. Start sewing.
3. “c1-1”, “c1-2”, “c1-3” are sewn in order for each article, and when the last-recorded pattern has been sewn, the
display returns to “c1-1".
*
*
If you press one of the DISPLAY SET switches (11) when “c1-*” is displayed, you can return to the previous stitch pattern or skip a stitch
pattern.
If you press the SELECT switch (3) when “c1-*” is displayed, you can check the contents of the recorded user program.
Clearing a cycle sewing program
1. Switch the machine to recording mode by the procedure in step 3. of recording a user program.
2. Use one of the P* switches (user program switches) to specify which cycle sewing program to clear.
*
Press the P1 switch (9) if you would like to clear cycle sewing program No.1. (“Pc 1” will be displayed.)
3. Press the RESET switch (12).
*
*
The recorded contents of the specified cycle sewing program will then be cleared.
If you press and hold the RESET switch (12) until after the buzzer has sounded twice, all cycle sewing programs will be cleared.
Note:
If you clear a user program after any cycle sewing programs have been recorded, all recorded cycle sewing programs will
also be cleared
BE-438C
53
14. TABLE OF ERROR CODES
14. TABLE OF ERROR CODES
DANGER
Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet
before opening the face plate of the control box. Touching areas where high voltages are present can result in
severe injury.
If a malfunction should occur with the sewing machine, a buzzer will sound and an error code will appear in the display
window. Follow the remedy procedure to eliminate the cause of the problem.
Code
E-13
E-17
E-20
E-21
E-30
E-31
E-32
Cause
Machine specification select connector is not
connected properly.
The foot switch was pressed or the operation
panel was used while the machine head was
tilted back, or the machine head was tilted back
while it was operating.
Problem with machine motor stopping, or synchronizer connection error. Or thermostat inside
sewing machine motor has operated.
Machine motor operation error.
Data is outside possible sewing area due to
enlargement ratio setting.
Stitch pattern data overlaps the sewing area
when area limiting is active.
The data format of the user program (% or mm)
does not match the setting of DIP switch A-6.
E-40
Length of a stitch exceeds 10 mm.
E-41
Abnormality in the sewing data.
E-42
Invalid program number specified.
E-50
Needle bar does not stop when the needle is
raised.
E-60
E-61
E-62
E-63
Presser has not been lowered.
Presser cannot be raised.
Presser is not raised.
Presser cannot be lowered.
E-70
Cooling fan does not operate.
E-80
Motor PROM is not correctly inserted.
Foot switch was depressed when the power was
turned on.
An operation panel switch was depressed when
the power was turned on.
E-81
E-82
Turn off the power, and then return the machine head to its
original position.
Turn off the power, and then turn the machine pulley to check
if the machine has locked up. Check the synchronizer
connection. Check if connectors P11, P12 and P13 are
disconnected.
Check that the correct combination of motor and PROM has
been installed.
Check if the sewing machine motor has overheated.
Turn off the power and check the ground wire connection.
Press the RESET switch, and then set the enlargement ratio
again.
Press the RESET switch, and then reset the memory
switches “30” and “31” or enlargement ratio.
After changing the setting of DIP switch A-6, clear all memory
settings. (Refer to “10-16. Clearing all memory settings”.)
Press the RESET switch, and then set the enlargement ratio
again.
If programming a new sewing data, repeat the procedure
from the beginning.
Press the RESET switch and specify a correct number.
Turn the pulley to align the index mark with the needle up
stop position. (Refer to “10-12. Adjusting the needle up stop
position”.)
Refer to “16. Troubleshooting”.
Turn off the power and check the connection of presser
sensor connector P1.
E-90
Abnormal drop in power supply voltage, or power
was turned on again immediately after it was
turned off.
E-91
Abnormal rise in power supply voltage.
54
Remedy
Turn off the power and check if connectors P3 is disconnected.
Turn off the power, and then check if the cooling fan is
blocked with scraps of thread.
Turn off the power and check.
Turn off the power and check.
Turn off the power and check the operation panel.
Check that all panel cords are normal.
Turn off the power and check the input voltage.
After turning off the power, wait 3 seconds or more before
turning it on again. (Refer to “10-15. Checking the input
voltage”.)
Turn off the power and check the input voltage. (Refer to
“10-15. Checking the input voltage”.)
BE-438C
14. TABLE OF ERROR CODES
Code
E-A0
E-b0
E-d0
E-E0
Cause
Home position cannot be detected (malfunction
of home position sensor), or malfunction of power
supply circuit board.
You tried to change the program number when
DIP switch A-8 was set to ON.
Heat sink of control circuit board is abnormally
hot.
Malfunction of EEPROM (malfunction of main
circuit board).
E-E1
Corrupted EEPROM data, or main PROM version
has been upgraded.
E-E2
Corrupted EEPROM control information data.
E-F0
E-F1
E-F2
Solenoid or feed motor short-circuit (malfunction
of main circuit board), or power relay is not
operating (malfunction of power supply circuit
board).
Bad connection in cable between power supply
circuit board and main circuit board.
Abnormal current detected in power supply circuit
board.
Remedy
Turn off the power and check the connection of home
position sensor connector P1.
Press the RESET switch.
Set DIP switch A-8 to OFF before trying to change the
program number.
Turn off the power and clean the air intake port of the box.
Turn off the power, and turn it back on. If the error continually
occurs, contact a qualified service technician.
Press the RESET switch to reset the error. However, the data
(memory switches, display and user programs) will be reset
to the backup data or initialized.
Press the RESET switch to reset the error. However, the data
(memory switches, display and user programs) will all be
initialized.
Turn off the power and contact a qualified service technician.
Turn off the power and check if connectors P16 is
disconnected.
Turn off the power and contact a qualified service technician.
<Errors generated when optional equipment is connected>
Code
Cause
Remedy
Turn the EMERGENCY STOP switch clockwise to release
the lock, and then press the RESET switch to reset the error.
Turn the EMERGENCY STOP switch clockwise to release
the lock, and then press the RESET switch to reset the error.
You can then press the STEP BACK switch to repeat the
sewing.
E-10
Emergency stop switch was pressed.
E-11
Emergency stop switch was pressed during
sewing.
E-12
Emergency stop switch is being continually
pressed, or emergency switch connection error.
Turn off the power and check.
Thread breakage detected.
Turn the EMERGENCY STOP switch clockwise to release
the lock, and then press the RESET switch to reset the error.
You can then press the STEP BACK switch to repeat the
sewing.
E-14
REFERENCE
segment LED alphabet
Panel display
Text display
A
b
c
d
BE-438C
E
F
6
H
L
o
55
15. GAUGE PARTS LIST
15. GAUGE PARTS LIST
• Feed plate
159971-001(Standard)
154665-101
154166-101
153833-101
153870-101
S49950-001
S49951-001
S49952-001
S49953-001
S49954-001
S49955-001 (1)
• Button clamp spacer
AR
S52075-001
BR
S52076-001(Standard)
CR
S52077-001
DR
S52078-001
AL
S52071-001
BL
S52072-001(Standard)
CL
S52073-001
DL
S52074-001
HU
S52079-001
HV
S52080-001
• Needle hole plate
HS
S40917-001
HT
S40925-001
HW
S52081-001
HX
S52082-001(Standard)
56
BE-438C
16. TROUBLESHOOTING
16. TROUBLESHOOTING
CAUTION
Turn off the power switch and disconnect the power cord before carrying out troubleshooting, otherwise the machine
will operate if the foot switch is depressed by mistake, which could result in injury.
Problem
Cause
Check
Remedy
Page
Button clamp does not
rise.
Button
clamp
lifter
amount is too great.
Distance between button
clamp and top of needle
plate
Adjust the height of the
button clamp to within 13
mm.
38
Button clamp is contacting thread wiper.
Thread wiper
position
Adjust the position of the
thread wiper.
40
Button clamp is not
lowered.
Presser lifter link is not
moving back.
Link return spring is unhooked.
Button
clamp
lift
amount is incorrect.
Incorrect
position
of
button clamp holder hook
assembly
Distance between button
clamp and top of needle
plate
Clearance
between
thread wiper and needle
tip
standby
Hook the link
spring properly.
return
Adjust the button clamp
lift amount.
38
Adjust the height of the
thread wiper.
40
Thread wiper position
Adjust the operating distance of the thread wiper.
40
Thread wiper position is
incorrect.
Thread wiper position
Adjust the operating distance of the thread wiper.
40
Lower thread winds to
one side.
Bobbin winder thread
tension stud height is
incorrect.
Bobbin winder thread
tension stud height
Adjust the height of the
thread tension stud.
23
Lower thread winding
amount is incorrect.
Bobbin presser position is
incorrect.
Thread winding amount
Adjust the position of the
bobbin presser.
23
Thread
comes
threaded.
Stitches being skipped at
the sewing start.
Refer to “Skipped stitches
occur”
Refer to “Skipped stitches
occur”
58
Uneven
length.
Upper thread length
Adjust the sub-tension.
25
Adjust the thread take-up
lever stroke.
35
Thread wiper does not
operate correctly.
un-
Upper thread breaks.
The thread wiper is obstructing the needle.
upper
thread
Upper thread is too short.
Thread
stroke
Upper thread tension is
too strong.
Upper thread tension
Adjust the upper thread
tension.
25
Needle is installed incorrectly.
Needle direction
Install the needle correctly.
22
Thread is too thick for the
needle.
Thread and needle
Use the correct thread for
the needle.
22
Thread take-up spring
tension and height
Adjust the tension and
height of the thread takeup spring.
25, 26
Damage or burring
File smooth or replace
the affected part.
Thread edge
Use a thread cooling
device (optional)
Thread take-up spring
tension and height are
incorrect.
Damaged
or
burred
rotary hook, needle hole
plate or needle.
Thread melting (synthetic
thread)
BE-438C
take-up
lever
60
57
16. TROUBLESHOOTING
Problem
Cause
Lower thread breaks.
Skipped stitches occur.
Remedy
Page
Lower thread tension
Adjust the lower thread
tension.
25
Damage
File smooth or replace
the affected part.
Needle clearance
Adjust the needle clearance.
34
Needle bar lift amount
Adjust the needle bar lift
amount.
33
Driver
is
contacting
needle more than is
necessary.
Clearance between driver
and needle
Adjust the driver needle
guard.
34
Needle is bent.
Bent needle
Replace the needle.
Needle is installed incorrectly.
Needle direction
Install the needle correctly.
22
Needle is striking the
button
Needle down setting
Refer to “6. CHECKING
THE
SEWING
PATTERN”.
21
Needle clearance
Adjust the needle clearance.
34
Needle bar lift amount.
Adjust the needle bar lift
amount.
33
Needle is bent.
Bent needle
Replace the needle.
Needle is too thin.
Needle and thread
Use the correct needle
for the material.
Movable knife is blunt.
Movable knife blade
Replace
knife.
Fixed knife is blunt.
Fixed knife blade
Sharpen or replace the
fixed knife.
37
Shuttle race thread guide
position
Adjust the position of the
shuttle race thread guide.
34
Needle bar lift amount
Adjust the needle bar lift
amount.
33
The movable knife does
not pick up the thread
because
of
skipped
stitches at the sewing
end.
Skipped stitches at sewing end
Refer to “Skipped stitches
occur”.
58
Movable knife position is
incorrect.
Movable knife position
Adjust the position of the
movable knife.
36
Sub-tension is too weak.
Sub-tension
Turn the sub-tension nut
to adjust the tension.
25
Lower thread tension is
too strong.
Corners of needle hole
plate or bobbin care are
damaged.
Clearance
between
needle and rotary hook
tip is too great.
Incorrect needle
rotary hook timing.
Needle breaks.
Check
and
Needle is touching the
rotary hook.
Upper thread is
trimmed.
not
Movable knife does not
pick up the thread.
58
BE-438C
the
movable
37
16. TROUBLESHOOTING
Problem
Thread jamming.
Poor seam finish on
reverse
side
of
material.
Incorrect
tightness.
thread
Button breaks.
Machine
does
not
operate when power is
turned on and foot
switch is depressed.
Cause
Check
Remedy
Page
Thread take-up spring
tension and height are
incorrect.
Thread take-up spring
tension and height
Adjust the tension and
height of the thread takeup spring.
25, 26
Incorrect needle
rotary hook timing.
Needle bar lift amount
Adjust the needle bar lift
amount.
33
Shuttle race thread guide
position
Adjust the position of the
shuttle race thread guide.
34
Shuttle race thread guide
position
Adjust the position of the
shuttle race thread guide.
34
Upper thread is not properly tight.
Upper thread tension
Adjust the upper thread
tension.
25
Uneven
length.
Upper thread length
Adjust the sub-tension.
25
Adjust the thread take-up
lever stroke.
35
and
Shuttle race thread guide
is not separating the
threads.
Shuttle race thread guide
is separating the threads
insufficiently.
upper
thread
Upper thread is too long.
Thread
stroke
Needle is striking the
button.
Needle down setting
Refer to “6. CHECKING
THE
SEWING
PATTERN”.
21
Upper thread tension is
too weak.
Upper thread tension
Adjust the upper thread
tension.
25
Lower thread tension is
too weak.
Lower thread tension
Adjust the lower thread
tension.
25
Thread take-up spring
tension and height are
incorrect.
Thread take-up spring
tension and height
Needle is striking the
button.
Needle down setting
Head position
does not work.
switch
take-up
lever
Adjust the tension and
height of the thread takeup spring.
Refer to “6. CHECKING
THE
SEWING
PATTERN”.
25, 26
21
Head position switch cord
connection
Check if the cord is disconnected.
12, 13
Switching plate position
Adjust the position of the
switching plate.
9
Head position switch is
broken.
Replace the head position switch.
BE-438C
59
17. OPTIONAL PARTS
17. OPTIONAL PARTS
Two-pedal foot switch
Two-step foot switch
0271Q
The presser switch and the start switch have been
separated, giving the operator more flexibility to select the
best method of working.
Liquid cooling tank
0272Q
This is a pedal-type foot switch.
Solenoid thread wiper
0273Q
0275Q
This helps to prevent thread breakage caused by friction
when using synthetic threads.
Fill the tank with silicone oil (100mm2/s).
This wipes the thread independently of the work clamp
operation.
Emergency stop switch
0276Q
If the emergency stop switch has been pressed during
sewing, the machine can be stop. And, you can move the
feed mechanism back in steps to the desired position and
then start sewing again.
60
BE-438C
INSTRUCTION MANUAL
15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177
Printed in Japan
118-V38
S91V38-202
2002.10.B(1)